Cut and seal method and apparatus

ABSTRACT

A fin sealer and method to seal a radially outwardly directed fin of a tubular web structure by directing the fin through a nip between a first and a second fin sealing rollers while communicating heat to the fin through at least one of the fin sealing rollers is provided. The fin sealer is configured to maintain a nominal face-to-face relation between an outer annulus of the first fin sealing roller and an outer annulus of the second fin sealing roller with a flexible connection between a hub element of the second fin sealing roller with the outer annulus of the second fin sealing roller.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.15/473,351, filed on Mar. 29, 2017, the entire contents which isincorporated herein by reference.

FIELD

This disclosure relates generally to systems and methods ofmanufacturing packets of flowable material and, more particularly, tosystems and methods of manufacturing packets (pouches) of smokelesstobacco for placement into containers in a continuous operation at greatspeed and reliability.

Environment

Various forms of smokeless tobacco, including pouched moist smokelesstobacco (MST) are provided to the consumer in a lidded cylindricalcontainer (can) that is constructed from metal, paperboard and/orplastic. Pouched MST or snus may comprise a measured portion ofsmokeless tobacco enclosed in a paper web that has been folded into apillow-like form and sealed such that it has a transverse, sealed seamat each end of the pillow-like form and a longitudinal seam extendingtherebetween.

With the ever-increasing consumption of smokeless tobacco and theadvantages of having individual portions prepackaged in a suitablepermeable pouch (packet), a need has arisen for large scale, high speed,reliable production and packaging of these rather small pouches(approximately 1.5 inch by ⅞ inch). A persistent challenge has been toreliably form individual packages in a continuous manner at elevatedrates of production which can meet demanding quality control and productspecifications.

More particularly, heretofore, techniques for automated production ofMST or snus packets have included forming the transverse seam of thepacket by a separate sealing operation followed by a separate cuttingoperation. Such arrangement necessitates synchronization of the twooperations and complicates “size changes” at the machine when it isdesired to produce a pouch of a different size on a machine that hasbeen already configured to produce pouches of a first size. Furthermore,the separate sealing operation generates a string of sealed, uncutpackets which requires an additional material handling operation betweenthe machine location of the sealing operation and the machine locationof the cutting operation. Misalignment of the string at the cutter dueto a failure, limitation or lapse of the material handling operation mayproduce skewed cuts at the transverse seam of the pouches, resulting inproduct that is inconsistent, possibly out of specification and/orvisually less acceptable to the consumer. In such systems, the risk ofmisalignment increases with machine speed and may arise during startupand shutdown of the system. Separation of the sealing and cuttingoperations has been used to avoid complications arising from attemptingto sever along a web seam that is still in a heated condition. At theinstance of sealing, the web may retain a degree of tackiness thatcauses the web (and the pouch) to stick to elements of the sealingstation. With separate sealing and cutting operations, the string ofsealed but yet to be cut pouches emanating from the sealing stationpulls the most recently formed uncut pouch away from components ofsealing station to overcome any sticking, but such action may cause thestring to oscillate or displace when sticking occurs. Accordingly,stickiness at the sealing operation can be a source of misalignment ofthe string of pouches at the cutter and create the aforementionedproblems associated with material handling between separate sealing andcutting stations. This risk of misalignment increases with machine speedand may arise during machine startup and shutdown.

Accordingly, there has been an unmet need for a method and apparatus toproduce snus pouches at high speed, but without resort to separatesealing and cutting operations of the pouches so as to promoteconsistency in product quality and appearance.

Furthermore, it would be desirous to provide a method and apparatus toproduce snus pouches in a manner which facilitates sealing and cuttingat transverse seam of the pouch in a single operation.

Additionally, it would be desirous to provide a method and apparatus toproduce snus pouches at high speed, in a manner which facilitatessealing and cutting at transverse seam of the pouch in a singleoperation which overcomes the risks of impacting product quality andappearance from tackiness at the seam.

SUMMARY

An aspect of the present disclosure provides a method of forming astream of individual packets comprising: rotating a knife, an anvil andsealing jaws into opposing relation at a nip, continuously forming atubular web structure and drawing the continuously formed tubular webstructure to the nip, repetitively sealing the continuously formedtubular web structure transversely at the nip by rotating sealing jawsinto opposing relation at the nip so as to seal a transverse portion ofthe tubular web structure, severing the continuously formed tubular webstructure at a location along the transverse sealed portion by rotatingthe anvil and the knife into an opposing relation at the nip against thetransversely sealed portion so as to form a severed, completed packetbeyond the nip, whereby a stream of completed packets is established,and further rotating the anvil, the knife and the sealing jaws into aproximal relation to a stripper element, whereby, should a completedpacket stick to any of the anvil, the knife and/or the sealing jaws, thestripper element releases the stuck completed packet from the anvil, theknife and/or the sealing jaw.

In an embodiment, the repetitively sealing and severing may also form apartially closed packet structure adjacent the nip and the continuouslyformation of a tubular web structure may include forming the tubular webstructure about a feed tube. The method may further comprise feedingthrough the feed tube a charge of flowable material into the partiallyclosed packet structure concertedly with the repetitively sealing andsevering.

Rotation of the sealing jaws, the anvil and the knife may be maintainedat a constant speed, including constant speed of rotation through thenip. Their rotation may comprise rotation of first and second rotorswhile supporting the knife and a first set of the sealing jaws on thefirst rotor and supporting the anvil and a second set of the sealingjaws on the second rotor, while also spring loading the knife, the anviland at least one of the first and second sets of the sealing jaws.

The knife, the anvil and the first and second sets of the sealing jawsmay be constructed from a hardened metal, whereby the hardened metal,the constant speed of rotor rotation and the spring loading of theknife, the anvil and at least one of the first and second sets of thesealing jaws facilitate a higher speed of the sealing and severing atthe nip than an operation lacking the hardened metal, the constant speedof rotor rotation and the spring loading.

The severing may include severing with a scissoring action wherein thesevering initiates on a side of the sealed portion of the tubular webstructure and progresses across the sealed portion to an opposite sideas the knife is rotated through the nip. The scissoring action mayinclude rotating a blade of the knife about an axis while maintainingthe knife blade at an angle with respect to the axis. In an embodiment,the angle is in the range of approximately 2 to approximately 6 degrees.

In an embodiment, the method may further comprise catching the severed,completed packets beyond the nip with a packet catcher having a lip,wherein the lip operates as the stripper. The method may further includeentraining completed packets by discharging a stream of gas downwardlyinto the catcher, whereby the catcher is cleared of completed packetsthrough an open end of the catcher below the nip.

In an embodiment, the method may further comprise directing the streamof completed packets through a pivotable sampling funnel andcontrollably pivoting the sampling funnel to and from a first positionand a second position. When at the first position, the sampling funneldirects the stream of completed packets in a first direction toward apacket receiving location for a container and when at the secondposition, the sampling funnel diverts the stream of completed packets ina second direction away from the packet receiving location for acontainer.

The method may further comprise directing the stream of completedpackets through a gated transfer funnel comprising a gate, includingholding back the stream of completed packets within the gated transferfunnel by closing the gate when a container is absent from the packetreceiving location and including opening the gate when a container ispositioned at the packet receiving location. Additionally, the methodmay further comprise counting the number of completed packets passing bya location along a path to the packet receiving location andcontrollably operating at least one of the sampling funnel and the gateof the gated transfer funnel to control delivery of completed packets toa container at the packet receiving location in accordance with apredetermined number of packets.

The method may further comprise delivering completed packets to acontainer in accordance with a predetermined number of packets at thepacket receiving location and thereafter controllably moving thecontainer from the packet receiving location to a second location andtamping the delivered completed packets at the second location. Themethod may further comprise executing a weight check upon the containerbeyond the second location, and adjusting the feeding of the flowablematerial responsively to the weight check so as to maintain consistencyof the feeding.

In an embodiment, the delivery includes simultaneous delivery to a setof containers with multiple streams of individual packets at a pluralityof the packet receiving locations and thereafter controllably moving theset of containers from the plurality of packet receiving locations to aplurality of the second locations and simultaneously tamping thedelivered completed packets of the set of containers at the plurality ofsecond locations.

The disclosed method may also include establishing a temperaturedifference (differential) at the nip by cooling at least one of therotors.

In an embodiment, the continuous formation of a tubular web structuremay include forming the tubular web structure with a radially outwardlydirected fin by mutually superimposing longitudinal edge portions of thetubular web structure and sealing the radially outwardly directed fin bydirecting the fin through a nip between first and second fin sealingrollers while communicating heat to the fin through at least one of thefin sealing rollers. The method may further comprise maintaining anominal face-to-face relation between outer annulus of the first finsealing roller and an outer annulus of the second fin sealing roller byflexibly connecting a hub of the second fin sealing roller with theouter annulus of the second fin sealing roller, whereby consistentsealing of the fin is enhanced.

Another aspect of the present disclosure provides an apparatus forforming a stream of individual packets, comprising a folder arranged toform a tubular web structure from a continuous ribbon of web, a feederarranged to feed the formed tubular web structure along a path to a nip;and a first rotor comprising a first sealing jaw and a knife adjacentthe first sealing jaw, a second rotor comprising a second sealing jawand an anvil adjacent the second sealing jaw. The first and secondrotors are mutually arranged so that upon rotation of the first andsecond rotors they rotate into opposing relation at the nip so as toseal a transverse portion of the tubular web structure and the knife andthe anvil rotate into an opposing relation at the nip to sever thetransversely sealed portion so as to form a severed, completed packetbeyond the nip. The apparatus includes an open ended packet catcheradjacent the first and second rotors which is arranged to catch thesevered, completed packets beyond the nip whereby a stream of packets isestablished. The packet catcher includes a stripper disposed in aproximal location to at least one of the anvil, the knife and thesealing jaws when the anvil, the knife and/or the sealing jaws arerotated beyond the nip, whereby, should a completed packet stick to anyof the anvil, the knife and/or the sealing jaws, the stripper isoperative to free the stuck packet from the anvil, the knife and/or thesealing jaw.

In an embodiment, the apparatus may further comprise an arrangement tocontrol rotation of the first and second rotors such that the sealingjaws, the anvil and the knife at a constant speed. Additionally, leastone of the knife and the anvil may be spring loaded and at least one ofthe first and second sealing jaws may be spring loaded. The knife, theanvil and the first and second sealing jaws may be constructed from ahardened metal, whereby the hardened metal, the constant speed of rotorrotation and the spring loading facilitate a higher speed of the sealingand severing at the nip than an operation lacking the hardened metal,the constant speed of rotor rotation and the spring loading.

The packet catcher may further comprise an arrangement to discharge astream of gas downwardly into the packet catcher, whereby the packetcatcher is cleared of completed packets through an open end of thecatcher below the nip. The packet catcher may include a side wall havingan arcuate upper wall portion configured to prevent a completed packetfrom escaping sideways.

In an embodiment, the apparatus may further comprise a pivotablesampling funnel that is controllably pivotal and operative as previouslydescribed above in regard to the corresponding disclosed methods. Theapparatus may further comprise a gated transfer funnel that may includea hold-back gate and a counter, which cooperate as previously describedabove with regard to the corresponding disclosed methods.

In an embodiment, the apparatus may further comprise deliveringcompleted packets to a container at the packet receiving location inaccordance with a predetermined number of packets and thereaftercontrollably moving the container from the packet receiving location toa second location and tamping the delivered completed packets at thesecond container location. The apparatus may further comprise a weightcheck operative upon the container at a third location beyond the secondlocation, and an arrangement to adjust the feeding of the flowablematerial responsively to output of the weight check so as to maintainconsistency of the feeding.

In another embodiment, the folder may be configured to superimposelongitudinal edge portions of the web to form a radially outwardlydirected fin and the apparatus may further comprise a fin sealerarranged to seal the radially outwardly directed fin by directing thefin through a nip between first and second fin sealing rollers whilecommunicating heat to the fin through at least one of the fin sealingrollers. The fin sealer may be arranged to maintain a nominalface-to-face relation between an outer annulus of the first fin sealingroller and an outer annulus of the second fin sealing roller with aflexible connection between the outer annulus of the second fin sealingroller and a hub component of the second fin sealing roller, wherebyconsistent sealing of the fin is enhanced.

In a further embodiment, the flexible connection may comprise a floatingroller and a flexible drive pin connection between the floating rollerand the hub component. In another further embodiment, the flexibleconnection may comprise a resilient disc operative between the centralcomponent and the outer annulus of the second fin sealing roller. In yetanother further embodiment, the flexible connection comprises a body ofelastic material operatively disposed between the hub component and theouter annulus of the second fin sealing roller.

Another aspect of the present disclosure provides a fin sealer andmethod to seal a radially outwardly directed fin of a tubular webstructure by directing the fin through a nip between a first and asecond fin sealing rollers while communicating heat to the fin throughat least one of the fin sealing rollers, the fin sealer being furtherarranged to maintain a nominal face-to-face relation between an outerannulus of the first fin sealing roller and an outer annulus of thesecond fin sealing roller with a flexible connection between a hub ofthe second fin sealing roller with the outer annulus of the second finsealing roller, whereby consistent sealing of the fin is enhanced.Further embodiments of the fin sealer are provided which correspond withthose described immediately above.

Yet another aspect of the present disclosure provides a method ofsealing a web body comprising supporting a first thermally conductivesealing jaw on a first rotor, supporting a second thermally conductivesealing jaw on a second rotor, rotating the first and second rotors tobring the first second sealing jaws into an opposing relation in contactwith the web body, and while rotating the first and second rotorsheating at least the first sealing jaw of the first rotor and coolingthe second rotor whereby transfer of heat from the first sealing jaw tothe second sealing jaw is promoted.

Further to that aspect, the aforementioned apparatus may include acooling system arranged to cool at least one of the first and secondrotors of the apparatus, and in an embodiment, the cooling system maycomprise a coaxial channel provided in one of the first and secondrotors and an open ended conduit coaxially disposed within the channel.The open ended conduit may be communicated with a source of coolant suchthat an incoming flow of coolant and a reversed flow of coolant may beestablished within the rotor.

BRIEF DESCRIPTION OF THE DRAWINGS

The forms disclosed herein are illustrated by way of example, and not byway of limitation, in the figures of the accompanying drawings and inwhich like reference numerals refer to similar elements and in which:

FIG. 1 is a planar side view of an exemplary tobacco pouch (packet)suited for manufacture in accordance with methods and apparatusdisclosed herein;

FIG. 2 is a perspective view of a container which has been loaded with anumber of tobacco pouches shown in FIG. 1;

FIG. 3 is top planar representation of an exemplary direct-to-can systemarranged to produce tobacco pouches to load them into container bottomsin accordance with an embodiment herein;

FIG. 4 is a perspective view of the exemplary system represented in FIG.3;

FIG. 5 is a frontal representation of a single machine lane L1 of theexemplary system represented in FIG. 3;

FIG. 6 is a side view of the single machine lane L1 represented in FIG.5;

FIG. 7 is a detail side view of the cut and seal component of the singlelane L1 shown in FIG. 6;

FIG. 8 is a detail planar view of the knife fixture as viewed in thedirection of arrow VIII in FIG. 7;

FIG. 9 is a detail planar view of the anvil fixture shown as viewed inthe direction of arrow IX in FIG. 7;

FIG. 10A is a perspective view of the anvil-bearing rotor shown in FIG.7;

FIG. 10B is a perspective view of the knife-bearing rotor shown in FIG.7;

FIG. 11A-C is a planar representation of the progression of cuttingaction “x” of the knife across a transverse sealed portion of the web;

FIG. 12 is a planar frontal view of an upper portion of the pouch makingmachine lane L1 as viewed in the direction of the double arrow XII-XIIin FIG. 6, in accordance with an embodiment of the present disclosure;

FIG. 13 is a cross-sectional representation of the feed rollers of theupper portion of the pouch making machine lane L1 as viewed in thedirection of arrow XIII in FIG. 12;

FIG. 14 is a representation of the plow of the upper portion of thepouch making machine lane L1 as viewed in the direction of arrow XV inFIG. 12;

FIG. 15 is a representation of the sealing rollers of the upper portionof the pouch making machine lane L1 as viewed in the direction of arrowXV in FIG. 12;

FIG. 16 (prior art) is a representation of sealing rollers in acondition of the extended use and in the absence of the teachingsherein;

FIG. 17A is a cross-sectional representation of sealing rollers whichinclude a flexible connection in accordance with an embodiment of theteachings herein;

FIG. 17B is a cross-sectional representation of sealing rollers whichinclude a flexible connection in accordance with the embodiment of FIG.17A, after extended use;

FIG. 18A is a planar front view of a roller assembly constructed inaccordance with an embodiment of the disclosure;

FIG. 18B is a cross sectional side view of a roller assembly of FIG.18A;

FIG. 18C is an exploded perspective view of a roller assembly of FIG.18A;

FIG. 18D is an exploded view of a roller assembly constructed inaccordance with another embodiment of the disclosure;

FIG. 19A is a perspective cutaway view of a roller assembly constructedin accordance with another embodiment of the disclosure;

FIG. 19B is a perspective cutaway view of a roller assembly constructedin accordance with another embodiment of the disclosure;

FIG. 20A is a perspective view of a roller assembly constructed inaccordance with yet another embodiment of the disclosure;

FIG. 20B is a cutaway perspective view of a roller assembly constructedin accordance with still another embodiment of the present disclosure;and

FIG. 21 is side view of rotors and a cooling system in accordance withan embodiment of the present disclosure, with one of the rotors andcertain components of the cooling system being shown in cross section.

DETAILED DESCRIPTION

Each of the following terms written in singular grammatical form: “a,”“an,” and “the,” as used herein, may also refer to, and encompass, aplurality of the stated entity or object, unless otherwise specificallydefined or stated herein, or, unless the context clearly dictatesotherwise. For example, the phrases “a device,” “an assembly,” “amechanism,” “a component,” and “an element,” as used herein, may alsorefer to, and encompass, a plurality of devices, a plurality ofassemblies, a plurality of mechanisms, a plurality of components, and aplurality of elements, respectively.

Each of the following terms: “includes,” “including,” “has,” “having,”“comprises,” and “comprising,” and, their linguistic or grammaticalvariants, derivatives, and/or conjugates, as used herein, means“including, but not limited to.”

Throughout the illustrative description, the examples, and the appendedclaims, a numerical value of a parameter, feature, object, or dimension,may be stated or described in terms of a numerical range format. It isto be fully understood that the stated numerical range format isprovided for illustrating implementation of the forms disclosed herein,and is not to be understood or construed as inflexibly limiting thescope of the forms disclosed herein.

Moreover, for stating or describing a numerical range, the phrase “in arange of between about a first numerical value and about a secondnumerical value,” is considered equivalent to, and means the same as,the phrase “in a range of from about a first numerical value to about asecond numerical value,” and, thus, the two equivalently meaning phrasesmay be used interchangeably.

It is to be understood that the various forms disclosed herein are notlimited in their application to the details of the order or sequence,and number, of steps or procedures, and sub-steps or sub-procedures, ofoperation or implementation of forms of the method or to the details oftype, composition, construction, arrangement, order and number of thesystem, system sub-units, devices, assemblies, sub-assemblies,mechanisms, structures, components, elements, and configurations, and,peripheral equipment, utilities, accessories, and materials of forms ofthe system, set forth in the following illustrative description,accompanying drawings, and examples, unless otherwise specificallystated herein. The apparatus, systems and methods disclosed herein canbe practiced or implemented according to various other alternative formsand in various other alternative ways.

It is also to be understood that all technical and scientific words,terms, and/or phrases, used herein throughout the present disclosurehave either the identical or similar meaning as commonly understood byone of ordinary skill in the art, unless otherwise specifically definedor stated herein. Phraseology, terminology, and, notation, employedherein throughout the present disclosure are for the purpose ofdescription and should not be regarded as limiting.

Specific forms will now be described further by way of example. Whilethe following examples demonstrate certain forms of the subject matterdisclosed herein, they are not to be interpreted as limiting the scopethereof, but rather as contributing to a complete description.

Throughout the teachings herein, separate references are made to acontroller C for controlling various elements of the disclosedembodiments. It is to be understood that each of those controllers maybe a single common controller C or several separate controllers C, whichmay be, but not necessarily, under a common control of a mastercontroller C.

Referring to FIGS. 1 and 2, this disclosure relates generally to systemsand methods of filling containers 10 with units of smokeless tobaccosuch as packets (pouches) 12 of moist smokeless tobacco (MST). By way ofnon-limiting example, the packet 12 may have a pillow-like shape andinclude an upper transverse seam 14, a lower transverse seam 16 andlongitudinal seam 18 extending therebetween. The longitudinal seam 18may be a lapped seam wherein longitudinal edges are overlapped andsealed together or a fin seam wherein longitudinal edges portions aredrawn together in an opposing relation so as to form an outwardextending fin, which is then sealed and folded against an adjacentregion of the pouch body. Regardless of which type of longitudinal seamis utilized, each pouch preferably contains a predetermined (metered,measured) portion of shredded tobacco in the form of moist smokelesstobacco (MST), but it is contemplated that the teachings herein wouldhave applications in the manufacture and packaging of pouches havingcontents, sizes and layouts other than what is specifically disclosedherein.

Referring particularly to FIG. 2, in an embodiment, the container 10 maybe in the form of puck-shaped can comprising a container bottom (cup) 20and a removable lid 22; however, the teachings herein are alsoapplicable to various containers of different sizes, shapes andconfigurations.

The present disclosure teaches a novel method and apparatus torepetitively produce a stream of individual pouches of smokeless tobaccoand to repetitively load predetermined number of packets into containersin a continuous operation with on-line weight control and other qualitycontrol features. According to aspects disclosed herein, a systemincludes a plurality of pouch making machines (lanes) that may operatecontinuously and in parallel.

A conveyor system may be structured and arranged to simultaneously movea plurality of empty containers into alignment with the plurality ofpouch making machines, such that the respective containers of a set aresimultaneously filled with pouches directly from respective ones of thepouch making machines (lanes L). The position of each container may betracked throughout the entire system by a controller, and each containermay be associated with the particular one of the pouch making machinesfrom which it was filled. Each container may be weighed after beingfilled, and at least one operational parameter of the pouch makingmachine associated with the weighed container may be adjusted based onthe weight of the container independently of the operation of the otherpouch making machines.

According to aspects described herein and in reference to FIG. 3, thepouch producing and loading system 25 may comprise a plurality of pouchproduction lanes L1, L2, . . . , LN, which are each configured toproduce a stream of individual pouches 12 and place (load) apredetermined number of pouches 12 into an individual container bottom20. In embodiments, the pouch producing and loading system 25 mayfurther comprise a tobacco feed system 26 comprising a plurality oftobacco feeders F1, F2, . . . , FN for repetitively feeding meteredamounts of flowable material such as MST (tobacco) into the pouchproduction machine lanes L1, L2, . . . , LN, and a tamping system 28comprising a plurality tamping stations T1, T2, . . . , TN for tampingthe pouches 12 that have been placed in the container bottoms 20 toavoid spill of product and to facilitate further handling andoperations, including placement of the lid 22 upon the loaded and tampedcontainer bottom 20. In embodiments, the feeders F may each comprise atwin screw feeder whose output is adjusted by controlling the amount ofrotation of the screws for each feed cycle. In other embodiments, thefeeders F may comprise a volumetric slide that moves one or moremetering cavities to and fro a first position where the cavity fills anda second position where the filled cavity is communicated with a pulsedjet of air, such as the feed system described in U.S. Provisional PatentApplication Ser. No. 62/199,110, which patent document is incorporatedherein by reference in its entirety for all purposes that may be servedherein. Further details and aspects of a “direct-to-can” system (asdescribed above in reference to FIGS. 1 and 2 herein) may be found in USPatent Publications Nos. 2014/0048170 and 2014/0047804, which patentdocuments are incorporated herein by reference in its entirety for allpurposes to be served herein.

In embodiments, the pouch producing and loading system 25 may furthercomprise a conveyor system 30 comprising a track 32 extending throughlocations of the production and loading lanes L1-LN and the tampingstations T1-T10 and a carousel 34 arranged to pick-up individualcontainer bottoms 20 from a feed station 36 and to repetitively movesets of the picked-up container bottoms 20 into position with the pouchproduction lanes L and then the tamping stations T, wherein the setscorrespond in number to that of the plurality of lanes L (and theplurality of tamping stations T).

Referring now also to FIG. 4, in embodiments, the carousel 34 maycomprise a plurality of spaced apart funnel cups 38 pivotally supportedfrom an endless conveyor and suitable motors and/or actuators controlledby a controller “C”. In implementations, the conveyor system 25 isstructured and arranged such that each funnel cup 38 engages an upperrim of an empty container bottom 20 at the feed station 36 and moves theempty container bottom 22 into position with one of the lanes L forexecution of a loading operation, whereupon the carousel moves thefunnel cup 38 and the engaged container bottom 20 to a correspondingtamping station T for execution of a tamping operation. Thereafter thecarousel moves the funnel cup 38 and the engaged container bottom 20 toan exit station 40 where the funnel cup 38 is raised to release thecontainer bottom 20. Upon its release, the loaded and tamped containerbottom 20 is directed to further packaging operations such as a lidder,labeler and boxer.

In embodiments, in lieu of or in addition, the carousel may comprise aplurality of carrier forks 39 (FIG. 6), which engage sidewalls ofindividual container bottoms 20 to move the container bottoms 20 in likemanner as the funnel cups 38.

In embodiments, a weight check station 42 may be arranged along thetrack 32 between the tamping stations (T1-T10) and the exit station 40and may be configured to weigh each loaded and tamped container bottom20 for purposes of providing the controller C with a signal indicativecontainer weight. The controller C may be configured to operate arejector 44 should the indicated weight of the loaded and tampedcontainer 20 be below a threshold weight that is indicative of thecontainer 20 missing one or more pouches. Because all of the pouches 12in a given container bottom 20 are produced from the same lane L andcorresponding feeder F, the controller C may also be configured toadjust feed rate at a corresponding feeder F responsively to signalsfrom weight check station 42 that are indicative of a trend in themeasured weight values for the given, corresponding feeder F away from anominal (specified) weight.

Referring now to FIGS. 5 and 6, in various embodiments each lane L, suchas by way of example L1, may comprise an (inlet) funnel 105 of a feedtube 110 which receives the output of the tobacco feeder F1 of the laneL1. In embodiments, a continuous ribbon of web 112 may be fed from asource of web such as a bobbin 114 to a folding collar 116 at locationalong the feed tube 110. The folding collar 116 is configured to foldthe continuous web 112 into a tubular web form 111 about the exterior ofthe feed tube 110. A pair of drive (drawing) rollers 118, 119 may beused to draw the tubular web form 111 downwardly along the feed tube 110toward a cut and seal station 130 comprising a knife-bearing rotor 132and an anvil-bearing rotor 134 and a pouch catcher/stripper chute 135. Asuitable motor M may controllably drive the drive rollers 118, 119,which may be controlled via signals from a controller C.

In embodiments, the folding collar 116 is configured to form a fin seam122 by outwardly folding longitudinal edge portions of the continuousribbon of web 112, which are then sealed into a mutually opposingrelation as the fin 122 is drawn through opposing, sealing rollers 124,126 (at least one of which is heated). Thereupon the fin 122 may befolded over against adjacent regions of the tubular web form 111 by aplow 128 or other suitable folding device. In other embodiments, thefolding collar 116 may be configured to fold the continuous web 112 intoa tubular body having a lapped seam, wherein a heated roller presses thelapped seam against an opposing portion of the feed tube 110 tothermo-mechanically seal the lapped seam.

In embodiments, at the location of the respective lane (L1), theknife-bearing rotor assembly 132 of the cut and seal station 130 maycomprise a first rotor body 133 to which is affixed a plurality of knifefixtures 136 at spaced locations about the periphery of the first rotorbody 133. In embodiments, each knife fixture 136 provides support for apair of mutually parallel, metallic sealing plates (jaws) 140, 141 and aknife 138 disposed therebetween. Referring now also to FIGS. 7 and 8,the metallic sealing jaws 140, 141 may extend axially (parallel to theaxis of rotation of the first rotor body 133), and the knife 138 mayextend generally coextensively with the metallic sealing jaws 140, 141but may be set at a small angle (approximately 2 to 6 degrees) offparallel. In embodiments, each knife 138 may be spring-loaded in aradially outward direction by a spring 142. For the production oftobacco loaded pouches, the edge of the knife 138 may extendapproximately 0.2 mm beyond the plane of the metallic sealing jaws 140,141. The metallic sealing jaws 140, 141 may be constructed of a hardenedsteel, they may include a coating and/or a highly polished work/contactsurface to minimize sticking with web material, and they may be rigidlyaffixed to the fixture 136 or in other embodiments, spring-loaded. In anembodiment, the sealing jaws 140, 141 may be outer surface portions of asingle fixture piece, and the knife may be operatively disposed in anopening that may be provided in the fixture piece between the sealingjaws 140, 141. Each fixture 136 may be provided with an electricallyresistive heating element 144 which may extend axially through thefixture 136 and may be communicated via a suitable (rotary) electricalconnection 148 to a source S of electrical power under the control of acontroller C. The heat generated by the electrically resistive heatingelement 144 is communicated to the metallic sealing jaws 140, 141through portions of the fixture 136 at a rate sufficient for maintainingthe metallic sealing jaws 140, 141 at an operating temperature at whichthey have the capacity to thermally seal the material of the web 112without scorching.

Referring now to FIGS. 7 and 9, in embodiments, the anvil-bearing rotorassembly 134 of the cut and seal station 130 may comprise a second rotorbody 151 to which is affixed a plurality of anvil fixtures 152 at spacedlocations about the periphery of the second rotor body 151. Inembodiments, each anvil fixture 152 provides support fora pair ofmutually parallel, metallic sealing plates (jaws) 154, 155 and a rigid,metallic, anvil body plate (anvil) 156 disposed therebetween. Themetallic sealing jaws 154, 155 may extend axially (parallel to the axisof rotation of the second rotor body 151), and the rigid, metallic,anvil 156 may extend generally coextensively with and parallel to themetallic sealing jaws 154, 155. In embodiments, each rigid, metallic,anvil 156 may be spring-loaded in a radially outward direction by aspring 158. The metallic sealing plates jaws 154, 155 may be constructedof a hardened steel, they may include a coating and/or a highly polishedwork/contact surface to minimize sticking with web material, and theymay be rigidly affixed to the fixture 136 or in other embodiments,spring-loaded. In an embodiment, the anvil 156 may be mounted in a fixedrelation with the sealing jaws 154, 155, with both the anvil 156 and thesealing jaws 154, 155 being spring-loaded by the spring 158. Eachfixture 152 may be provided with an electrically resistive heatingelement 160 which may extend axially through the fixture 152 and may becommunicated via a suitable (rotary) electrical connection 162 to asource S of electrical power under the control of a controller C. Theheat generated by the electrically resistive heating element 144 iscommunicated to the metallic sealing plates (jaws) 154, 155 throughportions of the fixture 152 at a rate sufficient for maintaining themetallic sealing jaws 154, 155 at an operating temperature at which theyhave the capacity to thermally seal the material of the web 112 withoutscorching.

Referring now to FIGS. 7, 10 a and 10 b, in an embodiment, the knifefixtures 136 of the knife-bearing rotor 132 and the anvil fixtures 152of the anvil-bearing rotor 134 may be arranged in four rows of ten thatare 90° apart from one another, although in different embodiments thenumber and the angular spacing may differ, so long as upon rotation ofthe rotors 132, 134, an anvil fixture 152 of the anvil bearing rotor 132is brought into an opposing relation with a knife fixture 136 of theknife bearing rotor 132 so as to define a nip 169 (FIG. 7) therebetween.The four rows of ten fixtures 136, 152 along the knife-bearing rotor 132and the anvil-bearing rotor 134, respectively, may correspond in numberand location to the number and location of the machine lanes L1 throughL10 of the embodiment shown in FIG. 1. It is envisioned that theteachings herein may be practiced with a different number of lanes L,even with but a single lane L, and accordingly, with a correspondingdifferent number of rows of fixtures 136, 152

In the absence of any pouch material at the nip 169, the metallicsealing jaws 140, 141 of the respective knife fixture 136 come intometal-to-metal contact with metallic, sealing jaws 154, 155 of the anvilfixture 152. One or both of the sets of sealing jaws (140,141) and/or(154,155) may be spring-loaded to accommodate for variations in shaftdiameter and run out along the shaft bodies 133, 151 of the knifebearing rotor 132 and the anvil bearing rotor 134, respectively.Likewise, at the nip 169 and in the absence of web material, the knife138 comes into contact with a bearing surface of the anvil body 156,with at least one, if not both of the knife 138 and the anvil body 156being spring-loaded so to accommodate for variations in shaft diameterand run out along the shaft bodies 133, 151 of the knife bearing rotor132 and the anvil bearing rotor 134, respectively.

The knife 138 and the bearing surface of the anvil body 156 may bepolished and/or coated to minimize a freshly formed pouch from stickingthereto.

Referring now to FIGS. 6 and 11A-C, as a knife fixture 136 and anopposing anvil fixture 152 rotate into and through the nip 169, the setsof sealing jaws (140,141) and/or (154,155) come into opposing actionagainst the tubular web form 111 being drawn into the nip 169, whichaction flattens a transverse portion of the tubular web form 111. Thesealing action of the opposing sets of sealing jaws (140,141) and(154,155) establish a transverse sealed region at the nip 169, whichregion is severed by the action of the knife 138 coming into opposingrelation to the anvil body 156. Because the knife 138 is set at a slightangle, the severing includes a scissoring action wherein the cuttingaction initiates (at “x” in FIG. 11A) on one side of the sealed region172 and progresses to the other side of the sealed region 172. Thisaction reduces the requisite cutting force and assures a consistent andcomplete severance at the sealed region 172 by the knife 138. It alsoaccommodates high speed operation of the cutter, such that 150 cycles aminute or higher such that 150 pouches per minute or more may beachieved with the cut and seal station 130. In addition, the disclosedarrangement produces transverse cuts that are straight, properly alignedand even, due at least in part to the metal-to-metal contact of theknife 138 and the anvil body 156 of the disclosed arrangement and theproximity of the knife 138 to the opposing sets of sealing jaws(140,141) and (154,155), which hold the web material in place whilecutting proceeds. The metal-to-metal contact of the knife 138 and theanvil body 156 of the disclosed arrangement also abates any need to slowdown the rotors 132,134 as they proceed into and through the nip 169 asis often required with rotor knives that work against opposing elastic(silicon) backstops. The disclosed arrangement can operate at a constant(and higher) speed while improving cut quality and consistency andsimplifying drive control of the rotors.

Referring again to FIG. 7, in embodiments, the knife-bearing rotor 132and the anvil-bearing rotor 134 may be driven by a suitable constantspeed motor M, whose speed may be optionally selectable to accommodatechanges in operating parameters and capabilities, which may be due tochanges in product size and/or other specifications. In embodiments, asingle motor M drives both rotors 132,134. through a phase-bar/anti-bindlinkage 170 between the rotors 132, 134, such that rotors 132, 134remain in phase with one another throughout start up, steady stateoperations and interruptions in operation.

Referring to FIG. 7, in embodiments, the pouch catcher/stripper chute135 of the cut and seal station 130 comprises an open ended boxstructure supported in a fixed relation to the knife bearing rotor 132and the anvil bearing rotor 134 such that as a pouch P is formed by thefilling, sealing and cutting of an individual pouch P at the rotors 132,134 and is released therefrom, the pouch P under gravity nominally fallsthrough the catcher/stripper chute 135 to enter the sampling chute 300.

In an embodiment, the pouch catcher/stripper chute 135 comprises a frontwall 200, a back wall 202 and side walls 204, 204′. Upper portions 206,206′ of the side walls 204, 204′ may each include arcuate edge portions207,208 which converge at an apex 209. The arcuate edge portions 207,208 may generally conform with but are spaced apart from the paths ofthe outermost portions of the knife fixtures 136 and the anvil fixtures152 during their rotation, which are represented by dashed lines 211,210, respectively. So configured, the upper portions 206, 206′ serve toprevent any a freshly completed pouch P that deflects sidewards off therotors 132, 134 from escaping.

In addition, the upper edge portions 212, 214 of the front 200 and theback wall 202, respectively are situated in close proximity to theaforementioned paths (arcuate sweep) 211, 210 of the fixtures 136, 152such that if any freshly completed pouch P were to stick to any of thesurfaces of the knife fixture 136 or of the anvil fixture 152, it isstripped or doctored therefrom by contact of the stuck pouch P with therespective upper edge portions 212 or 214 and directed into the pouchcatcher/stripper chute 135. For example, should a freshly formed pouchP1 stick to any of the sealing jaws 140, 141 or the knife 138 or anyother surface of the knife bearing fixture 136, it is carried along withthe respective fixture 136 along the arcuate path 211 until such timethe knife fixture 136 moves adjacent the upper edge portion 212 of thefront wall 200 of the pouch catcher stripper chute 125, whereupon thefreshly formed stuck pouch P1 is released into (and collected by) thepouch catcher/stripper chute 125.

In continuation of this example, should a freshly formed pouch P2 stickto any of the sealing jaws 154, 155 or the anvil 156 or any othersurface of the anvil fixture 152, it is carried along with therespective fixture 152 along the arcuate path 210 until such time theanvil fixture 136 moves adjacent the upper edge portion 214 of the backwall 202 of the pouch catcher/stripper chute 125, whereupon the freshlyformed stuck pouch P2 is released into the pouch catcher stripper chute125.

Accordingly, in embodiments, the upper edge portions 212, 214 serve asstrippers or doctoring knives to prevent the escape of pouches P thatmay stick to the elements of the rotors 132, 134. The upper edgeportions 212, 214 of the front and back walls 200. 202 together with thearcuate upper portions 206, 206′ of the side walls 204, 204′ thus assurecapture of all of the output of the cut and seal station 130 and assurethat the output is directed to the next element of the machine lane L1,which in the disclosed embodiment is a sampler funnel 300.

To further assure that all of the output of the cut and seal station 130is directed to the next element of the machine lane L1, the pouchcatcher/stripper chute 135 may be provided with air jet 220 to sweep(purge) the interior of the pouch catcher/stripper chute 135 of pouchesP that would otherwise collect or stick to locations within the pouchcatcher/stripper chute. In embodiments, the air jet 220 may comprisedownwardly directed nozzle 222 in communication with a source ofcompressed air or other suitable gas such as nitrogen, under control ofa controller C.

In embodiments, a lower portion 230 of the pouch catcher/stripper chute135 may include angulated front and back walls 232, 234 which aremutually arranged to induce and slightly forward component to thedirection of an exiting pouch P3, if desired. In other embodiments, thefront wall 200 may include a viewing window made of Plexiglas or othertransparent material to facilitate visual monitoring.

In embodiments, the pouch catcher/stripper chute 135 may includediscrete stripper and or doctoring units 215 in addition or in lieu ofusing the upper edge portions 212, 214 to strip stuck pouches from thefixtures 132, 134. In other embodiments the stripper units 215 maycomprise air jets.

Referring back to FIG. 6, upon release from pouch catcher/stripper chute135, a stream of pouches P enter a sampling funnel 300, which is pivotalbetween a first, operative position at which it directs the stream ofpouches P to the next component of the machine lane L and a samplingposition wherein sampling funnel 300 directs the stream of pouches awayfrom the next station for sampling or other purposes.

While the sampling funnel 300 is in the operative position, the streamof pouches P proceed to the next component of the machine lane L, whichin the disclosed embodiment comprises a transfer funnel 400. Inembodiments, the transfer funnel may include a holdback station (gate)410 to selectively permit or prevent the passage of pouches P throughthe transfer funnel 400. For example, the gate 410 may be selectivelymoved between a first position wherein the pouches P are allowed to passthrough the transfer funnel 400 to the next component of the machinelane L and a second position wherein further progress of the pouches Pis arrested (blocked). The gate 410 may be operative by action of asuitable motor M under the control of the controller C. In embodiments,the controller C may receive signals from a sensor S that counts thenumber of pouches P which may pass by a sensor eye 420 to control theopening and closing of the gate 410 responsively to the signal from thesensor S. Should a predetermined number of pouches the pass by thesensor eye 420, the controller C the closes the gate 410 until such timethat an unloaded container bottom 20 is brought into position at thelane L1. In embodiments, the controller may also open and close the gateresponsively to its tracking of the arrival and departure of a containerbottoms 20 at the lane L1, such that the gate 410 may be closed in theabsence of the can bottom 20 at the lane L1 until such time that a new,unloaded can bottom 20 arrives and is in position to receive pouches Pthrough the transfer funnel 400 and the funnel 38.

Referring now to FIG. 12, an aspect of the present disclosure alsoprovides a system comprising sealing rollers that achieve a morecomplete and consistent sealing of the fin seam by including anarrangement that overcomes a tendency of the sealing rollers to departfrom a squarely opposed surface-to-surface relationship at the nipbetween their working (bearing) surfaces due to wear and tear upondrive/support components.

More specifically, the present disclosure provides a system for sealinga fin seam, such that in a nominal condition, the working surfaces ofthe rollers are operative in a squarely opposed face-to-face relation.However, as time passes, wear and tear may loosen the drive and supportcomponents of the rollers such that one of the rollers may become cantedwith respect to the other roller. As a result, the working surfaces ofthe sealing rollers are no longer squarely opposed but instead areskewed (angulated to one another). When skewed, the rollers lose theircapacity to render complete and consistent sealing action along the finand tend to draw the web unevenly, which further degrades consistencyand quality of the fin seam.

The present disclosure provides methods and apparatus wherein a flexibleconnection is provided between the working surfaces of at least one ofthe rollers and its connection with its drive mechanism (hub), therebymaintaining the aforementioned nominal or near nominal squarely opposedrelation. When implemented, the disclosed arrangement provides improvedconsistency and robustness in the high speed production of the fin seamand extends the useful service life of the sealing rollers.

Referring now to FIGS. 12 and 13, in various embodiments each lane L,such as by way of example L1, may comprise an (inlet) funnel 105 forcommunicating the output of a tobacco feeder F1 with a feed tube 110 ofthe lane L1. In embodiments, a continuous ribbon of web 112 may be fedfrom a source of web such as a bobbin 114 to a folding collar 116 whichis configured at a location along the feed tube 110 to fold thecontinuous web 112 into a tubular web form 111 about the exterior of thefeed tube 110. A pair of drive (drawing) rollers 118, 119 that arebiased against the feed tube 110 may be used to draw the tubular webform 111 downwardly along the feed tube 110 toward a cut and sealstation 130. The cut and seal station 130 may comprise a knife-bearingrotor 132 and an anvil-bearing rotor 134 and a pouch catcher/stripperchute 135 as previously described. In an embodiment, the cutting andsealing may instead be performed at separate stations. A suitable motorM may controllably drive the drive rollers 118, 119. The motor M may becontrolled and synchronized via signals from a controller C. Each driveroller 118, 119 may be driven separately or by a single motor through asuitable drive link.

In embodiments, the folding collar 116 is configured to form a fin seam122 by outwardly folding longitudinal edge portions of the continuousribbon of web 112 into a mutually opposing relation. The resultant fin122 is then sealed together as the fin 122 is drawn through opposing,sealing rollers 124, 126 while at least one of which is being heated.Thereupon the fin 122 may be folded over against adjacent regions 121 ofthe tubular web form 111 by a plow 128 or other suitable folding device(FIG. 14). In other embodiments, the folding collar 116 may beconfigured to fold the continuous web 112 into a tubular body having alapped seam, wherein a heated roller, which is biased against anadjacent portion of the feed tube 110, thermo-mechanically seals thelapped seam.

Referring now to FIG. 15, in an embodiment, the right handed roller 126may be pivotally mounted to the machine frame of lane L1 on a pivotalarm 310 which is movable about a pivot axis 312, which allows the roller126 to be retracted and re-engaged during operations, such as a shutdownand a start up of lane L1. The right-hand roller 126 is heated by anelectrical a resistive heater 314 which is connected to a source ofelectrical power S under the control of a controller C. The right-handroller 126 may be driven by a suitable motor M under the control of acontroller C. The motor M may also drive the left-hand roller 124through a suitable drive linkage, such as an anti-skip/anti-bind drivelinkage, which may include suitable cogbelts and spur gears.Alternatively, either one of the rollers 124, 126 may be driven byseparate motors and with which are controlled and synchronized by thecontroller C.

Each of the rollers 124, 126 may be rotationally supported with suitablejournals or bearings (supports) 316, 316, respectively. When engaged,the working surfaces 318, 319 of the rollers 124, 126 are urged towardeach other against opposite sides of the fin 122 and the heatcommunicated to the surface 319 from the heater 314 of the right-handroller 126 is sufficient to thermo-mechanically seal the fin 122 as thefin 122 is drawn through the nip 320 between the sealing rollers 318,319. Nominally, the supports 316, 316 maintain the sealing rollers 124,126 in a mutually opposing relation such that their working surfaces318, 319 are in a nominal, squared-off, face-to-face relation such thatplane of the working surfaces 318, 319 at the nip 320 are parallel toone another.

Referring now to FIG. 16 (prior art), it has been discovered that as themachine L1 is operated, the journals (or bearings) J, J′ and other drivecomponents between the motor and the rollers A, B would loosen orotherwise degrade allowing at least one of the rollers such as roller Ain FIG. 16 to cant (skew) as shown in FIG. 15 away from the nominal,squared off face-to-face relation. When skewed, the rollers A, B of theprior art would impart an uneven/misaligned pressing action which woulddegrade the quality, strength and consistency of the seal along the fin122. The misalignment of the rollers A and B would also cause therollers A and B to pull on the paper unevenly, which would degradeproper tracking of paper through the rollers A, B.

Referring now to FIG. 17A, the present disclosure provides anarrangement to overcome the aforementioned deficiencies in the prior artas described in reference to FIG. 16. In the disclosed arrangement, theleft hand roller 124 may comprise a rotationally hub portion 324 whichmay be driven or undriven, a rigid outer annulus 325, which provides theworking surface 318, and a flexible connection 322 that is operativebetween the hub portion 324 and the outer rigid annulus 325 of theroller 124. In embodiments, the right hand roller 126 may also beprovided with a rigid connection 326 between its hub portion 324′ and arigid outer rigid annulus 325′ of the roller 126. In other embodiments,the right hand roller 126 may be provided with a flexible connection322′ such as described with reference to the roller 124, such thatrollers 124, 126 both have a flexible connection 324, 324′,respectively.

Referring now to FIG. 17B, with the disclosed arrangement, as the drivelinkage and/or the bearings, journals 316 of the roller 124 become wornor otherwise loose, the flexible connection 322 dissipates tendency ofsuch condition to cant the roller 124 such that the nominal squared offface-to-face relation between this working surfaces 318, 319 at the nip320 is maintained. With such action, the integrity of the seal along thefin 122 is conserved and product quality, i.e. a consistent, completesealing of the fin 122, is maintained. Proper paper tracking though thenip 320 between the sealing rollers 124, 126 is also maintained.

It is contemplated that in an embodiment such as shown in FIG. 15, theroller 126 may be provided with a drive connection (including a driveshaft 317′, bearings 316′ and other components) that become loose uponextended or heavy use, causing the roller 126 to cant away from itsnominal position as shown in FIG. 15. The opposing roller 124, beingprovided with a flexible connection 322 as previously described, has thecapacity to cant responsively to the canting the roller 326 to maintainnominal face-to-face relationship between the working surfaces 318, 319of the rollers 124, 126, thereby maintaining complete, consistentsealing and proper paper tracking.

Referring now to FIGS. 18A-C, in an embodiment, the roller 324 maycomprise a floating roller assembly 124′ whose components include a hubsleeve (hub) 400, a floating roller 402, a key 404 drivingly connectingthe hub sleeve 400 with an end portion 321 of the drive shaft 317, adrive pin 403 arranged to drivingly connect the roller 402 with the hubsleeve 400 at an aperture 405 provided in the floating roller 402, aretention cap 408 and a threaded fastener 410 adapted to affix theretention cap 408 to the end portion 321 of the drive shaft 317 in anaxial registration relative to the floating roller 402 such thatclearance is provided between the floating roller 402 and componentsadjacent to it. In embodiments, an axial clearance may be providedbetween the floating roller 402 and axially adjacent portions of the cap408 and/or the hub 400 and a radial clearance may be provided betweenthe floating roller 402 and radially adjacent portions of the endportion 321 of the drive shaft 317 and/or the retention cap 410. Thediameter of the aperture 405 in the roller 402 is oversized relative tothe diameter of the drive pin 403 such that a flexible drive pinconnection 412 is established between the hub sleeve 400 and the roller402. Should the floating roller 402 need to cant to compensate for acanting of the other, opposing roller 126, it may do so by reason of theaforementioned clearances and the aforementioned flexible drive pinconnection 412. The drive pin 403 may be press fitted into a hole 414provided in the hub sleeve 400 or otherwise affixed to the hub 400 by asuitable connection such as threaded connection, a twist-lock, a detentor the like. In an embodiment, the retention cap 408 may partiallyoverlap the aperture 405 of the roller wheel 402 as a further measure toassure that the drive pin 403 remains operatively in place. Inembodiments, the floating roller 402 includes a rigid outer annulus 325as described in reference to FIG. 17A.

Referring now to FIG. 18D, alternatively, an embodiment may be providedwith a key 404′ which includes an axial finger (drive pin) 403′ that isoperative like the drive pin 403 described in reference to FIGS. 18A-C,except that the drive pin 403′ and the key 404′ of FIG. 18D areintegrated. The main body of the key 404′ rotationally affixes the hubsleeve 400 with the end portion 321 of the drive shaft 317 and the axialextension 403′ fits into an aperture (notch) 405′ of the floating roller402′ with clearance so as to create a flexible drive pin connection412′. In embodiments, one or more spring washers 409 may be disposedbetween the retention cap 408 and the end portion 321 of the drive shaft317 to provide a desired spacing and/or biasing of the retention cap408.

Referring now to FIG. 19A, in another embodiment, the flexibleconnection 322 comprises a disc 500 of a resilient material such as aspring steel. The disc 500 is connected to the rigid outer annulus 325by a plurality of removable connectors 502 (such as small bolts, screws,pins and the like). The radially inward portion of the spring steel disc500 is retained by the hub (cap) 324 against the end portion 321 of theshaft 317, such as by way of a threaded connection 506 between anannular flange 507 of the hub 324 and an end portion 321 of the shaft317 upon which the roller 124 is mounted. Upon tightening, the threadedconnection clasps and registers the spring steel disc 500 between thehub 324 and an end portion of the shaft 317. With the describedarrangement, the disc 500 may be changed readily so as facilitatereplacement of worn out discs and/to change the flexibility of theflexible connection 322 by replacing a given disc 500 with one of agreater or lesser flexibility.

Referring now to FIG. 19B, another embodiment flexible connection 322comprises a disc 500 configured as described in previous embodimentswith reference to FIG. 19 A, but where a fastener 522 secures the cap(hub) 324 to the end portion 321 of the drive shaft 317.

Referring now to FIG. 20A, in another embodiment, the roller 124comprises an outer rigid annulus 325, a hub 324 which may be connectedto the drive shaft 317 with a key 319. A flexible connection 322 isestablished between the hub 324 and the outer rigid annulus 325 with anannular body 606 of resilient, elastomeric material. The annular body ofresilient, elastomeric material 606 may molded into the confines betweenthe hub 324 and the outer rigid annulus 325. As shown in FIG. 20B,alternatively, the annular body of resilient, elastomeric material 606may comprise a pre-formed, silicone washer that is fitted and retainedbetween the hub 324 and the outer rigid annulus 325.

In embodiments, the flexible connection 322 between a hub portion of theroller 124 and its outer rigid annular element 325 may comprise adiscrete cylindrical piece which connects to an end portion of the shaft317. In other embodiments, an end portion 321 of the drive shaft 317 maydefine at least in part the hub portion of the roller 124 as describedherein. The flexible connection 322 maintains the desired squared-off,face-to-face relation between working surfaces 318, 319 of the tworollers 124, 126 at the nip 320 so as to consistently achieve a completeand robust seal along the fin 122.

Referring now to FIG. 21, in an embodiment, the cut and seal station 130may include a rotor cooling system 700 arranged to circulate a coolantfluid (such as water or air) through one of the rotors 132, 134 such asthe knife bearing rotor 132 by way of example. The cooling system 700 isarranged and operated such that a temperature differential (difference)is established between the knife bearing fixture 136 and the anvilbearing fixture 152 at the nip 169 to promote establishment of a moreimmediate and robust seal.

In an exemplary embodiment the rotor cooling system 700 may be appliedto the knife bearing rotor 132 (but not the anvil bearing rotor 134),whereby the heater element 144 and the coolant system 700 maybe operatedto bring the the sealing jaws 140, 141 of the knife bearing rotor 132 toa desireable, lower operating temperature relative to the operatingtemperature of the heated (uncooled) sealing jaws 154,155 of the anvilbearing rotor 134. The resultant difference in operating temperature maybe utilized to drive a transfer of heat from more heated sealing jaws154,155 of the anvil bearing rotor 134 across the web being sealed tothe less heated sealing jaws 140, 141 of the knife bearing rotor 132.The metallic (heat conductive) nature of both sets of sealing jaws 140,141 and 154,155 facilitates establishment of the aforementionedtemperature differential and heat transfer.

In an embodiment, the rotor cooling system 700 may comprise alongitudinal channel 702 extending into the knife rotor 132 into whichis extended is a coaxial conduit (pipe) 704. In embodiments, the kniferotor 132, the channel 702 and the conduit are mutually concentric, andthe channel 702 may extend approximately 80% of the working extent ofthe knife rotor 132 (e.g. 80% of the extent of lanes L1-L10 of theexemplary embodiment). A distal end portion 708 of the conduit 704 mayterminate short of the full extent of the channel 702 such that theconduit 704 is open ended within the channel 702. Coolant fluid such aswater may be pumped from a source S by a suitable pump P into theconduit 704 by a suitable rotary coupling 706 that communicates with theconduit 704. At the distal end portion 708 of the conduit 704, thecoolant flow may discharge from the conduit 702 and return as a reversedflow along an annular channel 703 defined between the exterior 710 ofthe conduit 704 and an interior surface 712 of the channel 702. At therotary coupling 706 the reversed flow of coolant may be discharged ordirected back to the source S for recirculation. In embodiments,recirculation may include a suitable heat exchanger, filter and/or aflow controller. The conduit 704 may be affixed to the knife rotor 132so as to rotate therewith or be suspended by suitable supports such thatconduit 704 remains fixed while the knife rotor 132 rotates about theconduit 704.

The coolant flow established by the rotor cooling system 700 reduces thetemperature of the knife bearing fixture 136 relative to the anvilbearing fixture 152 at the nip 169 such that a thermal differential isestablished at the nip 139 such that heat may be favorably drawn in thedirection of arrow 712 from the hotter, anvil bearing fixture 152 of theanvil rotor 134 through the paper seal at the nip 169 into the coolerknife bearing fixture 136 of the knife rotor 132. The thermaldifferential may be configured to promote a consistent sealing operationand potentially allow for a lower total operating temperature at the nip169 and along the knife rotor 132. When the knife rotor 132 is disposedon the “operator side” of the machine, cooling of the knife rotor 132with the cooling system 700 may help abate thermal risks/discomforts tomachine operators during machine operations. The cooling system may bealso be configured and operated to make the process more forgiving as tovariations in heat generation and transfer from the heater elements144,160 of the knife bearing and anvil bearing fixtures 136,152,respectively.

It is envisioned that the rotor cooling system 700 may be appliedinstead or in addition to the anvil bearing rotor 134. In allapplications, the heaters 144 of the knife bearing fixtures 136 and theheaters 160 of the anvil bearing fixtures 152 could be operated asdescribed previously or that one or the other may be operated in areduced capacity or not at all so as to optimize heat transfer at thenip 169 and for other purposes such as described with regard to thecooling system 700.

It is contemplated that all of the above teachings herein would haveapplications in the manufacture and packaging of various (different)pouched articles of various (different) contents, sizes and layouts inaddition to those specifically disclosed herein; and that the teachingsherein would have applications to various containers for the pouchedarticles of various (different) sizes, shapes and configurations inaddition to those specifically described herein.

US/PCT 1. A method of forming a stream of individual packets comprising:rotating a knife, an anvil and sealing jaws into opposing relation at anip; continuously forming a tubular web structure and drawing thecontinuously formed tubular web structure to the nip; repetitivelysealing the continuously formed tubular web structure transversely atthe nip by rotating sealing jaws into opposing relation at the nip so asto seal a transverse portion of the tubular web structure; severing thecontinuously formed tubular web structure at a location along thetransverse sealed portion by rotating the anvil and the knife into anopposing relation at the nip against the transversely sealed portion soas to form a severed, completed packet beyond the nip, whereby a streamof completed packets is established; and further rotating the anvil, theknife and the sealing jaws into a proximal relation to a stripperelement, whereby, should a completed packet stick to any of the anvil,the knife and/or the sealing jaws, the stripper element releases thestuck completed packet from the anvil, the knife and/or the sealing jaw.

US/PCT 2. The method of US/PCT 1, wherein the repetitively sealing andsevering also forms a partially closed packet structure adjacent thenip, the continuously forming a tubular web structure including formingthe tubular web structure about a feed tube, the method furthercomprising feeding through the feed tube a charge of flowable materialinto the partially closed packet structure concertedly with therepetitively sealing and severing.

US/PCT 3. The method of US/PCT 1, wherein a speed of the rotating of thesealing jaws, the anvil and the knife is maintained constant, includingconstant speed of rotation through the nip.

US/PCT 4. The method of US/PCT 3, wherein the rotating of a knife, ananvil and sealing jaws into opposing relation at a nip comprisesrotating a first rotor and a second rotor while supporting the knife anda first set of the sealing jaws on the first rotor and supporting theanvil and a second set of the sealing jaws on the second rotor and whilespring loading the knife, the anvil and at least one of the first andsecond sets of the sealing jaws.

US/PCT 5. The method of US/PCT 4, wherein the knife, the anvil and thefirst and second sets of the sealing jaws are constructed from ahardened metal, whereby the hardened metal, the constant speed of rotorrotation and the spring loading of the knife, the anvil and at least oneof the first and second sets of the sealing jaws facilitate a higherspeed of the sealing and severing at the nip than an operation lackingthe hardened metal, the constant speed of rotor rotation and the springloading.

US/PCT 6. The method of US/PCT 5, wherein the severing includes severingwith a scissoring action wherein the severing initiates on a side of thesealed portion of the tubular web structure and progresses across thesealed portion to an opposite side as the knife is rotated through thenip, the scissoring action includes rotating a blade of the knife aboutan axis while maintaining the knife blade at an angle with respect tothe axis.

US/PCT 7. The method of US/PCT 6, wherein the angle is in the range ofapproximately 2 to approximately 6 degrees.

US/PCT 8. The method of US/PCT 1, further comprising catching thesevered, completed packets beyond the nip with a packet catcher having alip, wherein the lip operates as the stripper.

US/PCT 9. The method of US/PCT 8 further comprising entraining completedpackets by discharging a stream of gas downwardly into the catcher,whereby the catcher is cleared of completed packets through an open endof the catcher below the nip.

US/PCT 10. The method of US/PCT 5, wherein the rotating of the sealingjaws, the anvil and the knife include rotating first and second rotorswhile supporting the knife on the first rotor between members of thefirst set of sealing jaws and supporting the anvil and on the secondrotor between members of the second set of sealing jaws.

US/PCT 11. The method of US/PCT 10, wherein the supporting of the knifeand a first set of sealing jaws includes spring loading the knife andwherein the supporting of the anvil and the second set of sealing jawsincludes spring loading both the anvil and the second set of sealingjaws.

US/PCT 12. The method of US/PCT 11, wherein the supporting of the knifeincludes supporting a blade of the knife at an angle with respect to anaxis of rotation of the first rotor.

US/PCT 13. The method of US/PCT 8, further comprising directing thestream of completed packets through a pivotable sampling funnel andcontrollably pivoting the sampling funnel to and from a first positionand a second position, when at the first position the sampling funneldirecting the stream of completed packets in a first direction toward apacket receiving location for a container and when at the secondposition the sampling funnel diverting the stream of completed packetsin a second direction away from the packet receiving location for acontainer.

US/PCT 14. The method of US/PCT 13, further comprising directing thestream of completed packets through a gated transfer funnel comprising agate, including holding back the stream of completed packets within thegated transfer funnel by closing the gate when a container is absentfrom the packet receiving location and including opening the gate when acontainer is positioned at the packet receiving location.

US/PCT 15. The method of US/PCT 14, further comprising counting thenumber of completed packets passing by a location along a path to thepacket receiving location and controllably operating at least one of thesampling funnel and the gate of the gated transfer funnel to controldelivery of completed packets to a container at the packet receivinglocation in accordance with a predetermined number of packets.

US/PCT 16. The method of US/PCT 15, further comprising deliveringcompleted packets to a container in accordance with a predeterminednumber of packets at the packet receiving location and thereaftercontrollably moving the container from the packet receiving location toa second location and tamping the delivered completed packets at thesecond location.

US/PCT 17. The method of US/PCT 16, further comprising executing aweight check upon the container beyond the second location, andadjusting the feeding of the flowable material responsively to theweight check so as to maintain consistency of the feeding.

US/PCT 18. The method of US/PCT 17, wherein the delivery includessimultaneously delivering to a set of containers with multiple streamsof individual packets at a plurality of the packet receiving locationsand thereafter controllably moving the set of containers from theplurality of packet receiving locations to a plurality of the secondlocations and simultaneously tamping the delivered completed packets ofthe set of containers at the plurality of second locations.

US/PCT 19. The method of US/PCT 2, wherein the continuous formation of atubular web structure includes forming the tubular web structure with aradially outwardly directed fin by mutually superimposing longitudinaledge portions of the tubular web structure and sealing the radiallyoutwardly directed fin by directing the fin through a nip between firstand second fin sealing rollers while communicating heat to the finthrough at least one of the fin sealing rollers.

US/PCT 20. The method of US/PCT 19 further comprising maintaining anominal face-to-face relation between outer annulus of the first finsealing roller and an outer annulus of the second fin sealing roller byflexibly connecting a hub component of the second fin sealing rollerwith the outer annulus of the second fin sealing roller, wherebyconsistent sealing of the fin is enhanced.

US/PCT 21. The method of US/PCT 4 further comprising establishing atemperature difference at the nip by cooling at least one of the firstand second rotors.

US/PCT 22. The method of US/PCT 2, wherein the flowable materialcomprises tobacco.

US/PCT 23. An apparatus for forming a stream of individual packets,comprising: a folder arranged to form a tubular web structure from acontinuous ribbon of web; a feeder arranged to feed the formed tubularweb structure along a path to a nip; a first rotor comprising a firstsealing jaw and a knife adjacent the first sealing jaw; a second rotorcomprising a second sealing jaw and an anvil adjacent the second sealingjaw; the first and second rotors mutually arranged so that upon rotationof the first and second rotors: the first and second sealing jaws rotateinto opposing relation at the nip so as to seal a transverse portion ofthe tubular web structure; the knife and the anvil rotate into anopposing relation at the nip to sever the transversely sealed portion soas to form a severed, completed packet beyond the nip; and an open endedpacket catcher adjacent the first and second rotors and arranged tocatch the severed, completed packets beyond the nip whereby a stream ofpackets is established, the packet catcher including a stripper disposedin a proximal location to at least one of the anvil, the knife and thesealing jaws when the anvil, the knife and/or the sealing jaws arerotated beyond the nip, whereby, should a completed packet stick to anyof the anvil, the knife and/or the sealing jaws, the stripper isoperative to free the stuck packet from the anvil, the knife and/or thesealing jaw.

US/PCT 24. The apparatus of US/PCT 23, wherein the sealing and severingalso forms a partially closed packet structure adjacent the nip, thefolder arranged to form a tubular web structure about a feed tube, theapparatus further comprising a material feeder arranged to feed throughthe feed tube a charge of flowable material into the partially closedpacket structure concertedly with the sealing of the sealing jaws andsevering of the knife and anvil.

US/PCT 25. The apparatus of US/PCT 23, further comprising an arrangementto control rotation of the first and second rotors such that the sealingjaws, the anvil and the knife are rotated at a constant speed, includingconstant speed of rotation through the nip.

US/PCT 26. The apparatus of US/PCT 25, wherein at least one of the knifeand the anvil are spring loaded and at least one of the first and secondsealing jaws are spring loaded and wherein the knife, the anvil and thefirst and second sealing jaws are constructed from a hardened metal,whereby the hardened metal, the constant speed of rotor rotation and thespring loading facilitate a higher speed of the sealing and severing atthe nip than an operation lacking the hardened metal, the constant speedof rotor rotation and the spring loading.

US/PCT 27. The apparatus of US/PCT 23, wherein the severing includessevering with a scissoring action wherein the severing initiates on aside of the sealed portion of the tubular web structure and progressesacross the sealed portion to an opposite side as the knife is rotatedthrough the nip.

US/PCT 28. The apparatus of US/PCT 27, wherein the scissoring actionincludes rotating a blade of the knife about the axis of rotation of thefirst rotor while maintaining the knife blade at an angle with respectto the axis of rotation.

US/PCT 29. The apparatus of US/PCT 28, wherein the angle is in the rangeof approximately 2 to approximately 6 degrees.

US/PCT 30. The apparatus of US/PCT 23, wherein the packet catcherfurther comprises an arrangement to discharge a stream of gas downwardlyinto the packet catcher, whereby the packet catcher is cleared ofcompleted packets through an open end of the catcher below the nip.

US/PCT 31. The apparatus of US/PCT 24, wherein the packet catchercomprises a side wall having an arcuate upper wall portion configured toprevent a completed packet from escaping sideways.

US/PCT 32. The apparatus of US/PCT 31, further comprising a springloaded mount between the first rotor and the knife and a spring loadedmount between the second rotor and both the anvil and the second sealingjaw and wherein the mount of the knife maintains a blade of the knife atan angle with respect to an axis of rotation of the first rotor.

US/PCT 33. The apparatus of US/PCT 24, further comprising a pivotablesampling funnel positioned to receive the stream of completed packetsand controllable pivot operative to pivot the sampling funnel to andfrom a first position and a second position, when at the first positionthe sampling funnel operative to direct the stream of completed packetsin a first direction toward a packet receiving location for a containerand when at the second position the sampling funnel operative to divertthe stream of completed packets in a second direction away from thepacket receiving location.

US/PCT 34. The apparatus of US/PCT 33, further comprising a gatedtransfer funnel positioned to receive the stream of completed packets,the gated transfer funnel including a hold-back gate operative to retainmembers of the stream of completed packets within the gated transferfunnel upon closure of the gate when a container is positioned otherthan at the packet receiving location and the gate being controllablyopened when a container is positioned at the packet receiving location.

US/PCT 35. The apparatus of US/PCT 34, further comprising a counterarranged to count packets passing by a location along a path to thepacket receiving location and a controller configured to controllablyoperate at least one of the sampling funnel and the hold-back gate ofthe gated transfer funnel to control delivery of completed packets to acontainer at the packet receiving location in accordance with apredetermined number of packets.

US/PCT 36. The apparatus of US/PCT 35, further comprising deliveringcompleted packets to a container at the packet receiving location inaccordance with a predetermined number of packets and thereaftercontrollably moving the container from the packet receiving location toa second location and tamping the delivered completed packets at thesecond container location.

US/PCT 37. The apparatus of US/PCT 36, further comprising a weight checkoperative upon the container at a third container location beyond thesecond location, and an arrangement to adjust the feeding of theflowable material responsively to output of the weight check so as tomaintain consistency of the feeding.

US/PCT 38. The apparatus of US/PCT 23 further comprising a coolingsystem arranged to cool at least one of the first and second rotors.

US/PCT 39. The apparatus of US/PCT 38, wherein the cooling systemcomprises a coaxial channel provided in the at least one of the firstand second rotors and an open ended conduit coaxially disposed withinthe channel, the open ended conduit in communication with a source ofcoolant such that an incoming flow of coolant and a reversed flow ofcoolant is established within the at least one of the first and secondrotors.

US/PCT 40. A system comprising an array of packet producing lanes, eachlane comprising the apparatus of US/PCT 37, the system furthercomprising a conveyor arrangement controllably operative to repetitivelymove sets of containers to a corresponding set of the packet receivinglocations at the lanes whereupon the lanes deliver a counted stream ofcompleted packets to each container of the container set simultaneously,and thereafter the conveyor controllably moves the set of containersfrom the set of the packet receiving locations to a corresponding set ofthe second container locations whereupon the delivered completed packetsof the container set are simultaneously tamped.

US/PCT 41. The apparatus of US/PCT 24, wherein the feeder comprises arotating drive roller in proximity of the feed tube such that thetubular web structure is drawn along the feed tube by rotation of thedrive roller.

US/PCT 42. The apparatus of US/PCT 41, wherein the feeder comprises apair of drive rollers operative at opposite sides of the feed tube.

US/PCT 43. The apparatus of US/PCT 24, wherein the folder is configuredto superimpose longitudinal edge portions of the web to form a radiallyoutwardly directed fin.

US/PCT 44. The apparatus of US/PCT 43 further comprising a fin sealerarranged to seal the radially outwardly directed fin by directing thefin through a nip between first and second fin sealing rollers whilecommunicating heat to the fin through at least one of the fin sealingrollers.

US/PCT 45. The apparatus of US/PCT 44, wherein the fin sealer isarranged further to maintain a nominal face-to-face relation between anouter annulus of the first fin sealing roller and an outer annulus ofthe second fin sealing roller with a flexible connection between theouter annulus of the second fin sealing roller and a hub component ofthe second fin sealing roller, whereby consistent sealing of the fin isenhanced.

US/PCT 46. The apparatus of US/PCT 45, wherein the flexible connectioncomprises a floating roller and a flexible, drive pin connection betweenthe floating roller and the hub component.

US/PCT 47. The apparatus of US/PCT 46, wherein the flexible connectionincludes a compression washer.

US/PCT 48. The apparatus of US/PCT 45, wherein the flexible connectioncomprises an annulus of elastic material operatively disposed betweenthe hub component and the outer annulus of the second fin sealingroller.

US/PCT 49. The apparatus of US/PCT 45, wherein the flexible connectioncomprises a disc of spring steel operatively disposed between the hubcomponent and the outer annulus of the second fin sealing roller.

US/PCT 50. The apparatus of US/PCT 24, wherein the material feedercomprises a screw feeder having a controlled, adjustable output as afunction of rotation of the screw feeder for each feed cycle.

US/PCT 51. The apparatus of US/PCT 24, wherein the material feedercomprises an arrangement that pneumatically delivers volumetricallyestablished charges of the flowable material.

US/PCT 52. The apparatus of US/PCT 23 further comprising a coolingsystem arranged to cool at least one of the first and second rotors.

US/PCT 53. The apparatus of US/PCT 52, wherein the cooling systemcomprises a coaxial channel provided in the at least one of the firstand second rotors and an open ended conduit coaxially disposed withinthe channel, the open ended conduit in communication with a source ofcoolant such that an incoming flow of coolant and a reversed flow ofcoolant is established within the at least one of the first and secondrotors.

US/PCT 54. The apparatus of US/PCT 24, wherein the flowable materialcomprises tobacco.

US/PCT 55. An automated method of forming a transverse, cut seam of apacket, comprising: thermally sealing and severing a transverse seam byrotating sealing jaws, a knife and an anvil into opposing relation at asingle nip; collecting the completed packets with a packet catcher; andfurther rotating the anvil, the knife and the sealing jaws into aproximal relation to a lip of a packet collector, whereby, should acompleted packet stick to any of the anvil, the knife and/or the sealingjaws, the stuck packet is removed from the anvil, the knife and/or thesealing jaw.

US/PCT 56. A fin-sealing component of a packet making machine,comprising: a first roller comprising: a hub; a rigid outer annulusarranged to rotatably bear against a first side of a fin of a tubularweb structure; and a heater in thermal communication with the rigidouter annulus of the first roller to transfer heat to the fin sufficientto seal the web along the fin as the fin is contacted with the rigidouter annulus of the first roller; a second roller comprising: a rigidouter annulus arranged to rotatably bear against an opposite side of thefin in an opposing, nominally face-to-face relation with the rigid outerannulus of the first roller; and a support of the rigid outer annulus ofthe second roller comprising a hub and a flexible connection operativebetween the hub and the rigid outer annulus of the second roller, theflexible connection operative to maintain the face-to-face relationbetween the rigid outer annulus of the first roller and the rigid outerannulus of the second roller, whereby consistent sealing of the fin sealis enhanced.

US/PCT 57. The fin-sealing component of US/PCT 56, wherein the flexibleconnection maintains the face-to-face relation by counteracting atendency of an off-axis displacement of the hub of the first and/or thesecond roller to cant the respective rigid outer annulus of the firstand second rollers away from the nominal face-to-face relation.

US/PCT 58. The fin-sealing component of US/PCT 56, wherein the firstroller further comprises a driven support mechanism to support andcontrollably drive rotation the hub and the rigid outer annulus of thefirst roller, the driven support including a pivotal arm arranged topivot the rigid outer annulus of the first roller between an operatingposition and a retracted position.

US/PCT 59. The fin-sealing component of US/PCT 56, wherein the secondroller further comprises a driven support mechanism to support andcontrollably drive rotation of the hub and the rigid outer annulus ofthe second roller.

US/PCT 60. The fin-sealing component of US/PCT 56, wherein the flexibleconnection comprises a floating roller and a flexible, drive pinconnection between the floating roller and the hub.

US/PCT 61. The fin-sealing component of US/PCT 60, wherein the flexibleconnection further comprises a compression washer.

US/PCT 62. The fin-sealing component of US/PCT 56, wherein the flexibleconnection comprises a disc of spring steel operative between the huband the rigid outer annulus of the second fin sealing roller.

US/PCT 63. The fin-sealing component of US/PCT 56, wherein the flexibleconnection comprises a body of elastic material operatively disposedbetween the hub and the outer annulus of the second fin sealing roller.

US/PCT 64. The fin-sealing component of US/PCT 56, further comprising: afolder configured to form from a continuous ribbon of web a tubular webstructure having a radially outwardly directed fin comprising mutuallysuperimposed longitudinal edge portions of the web; and a feederarranged to draw a continuous ribbon of web through the folder and alonga path beyond the folder to a location of the first and second rollers.

US/PCT 65. A fin sealer arranged to seal a radially outwardly directedfin of a tubular web structure by directing the fin through a nipbetween a first and a second fin sealing rollers while communicatingheat to the fin through at least one of the fin sealing rollers, the finsealer being further arranged to maintain a nominal face-to-facerelation between an outer annulus of the first fin sealing roller and anouter annulus of the second fin sealing roller with a flexibleconnection between a hub element of at least one of the first and secondfin sealing rollers with the outer annulus of the respective first andsecond fin sealing rollers, whereby consistent sealing of the fin isenhanced.

US/PCT 66. The fin sealer of US/PCT 65, wherein heat is communicated tothe fin through the first fin sealing roller.

US/PCT 67. The fin sealer of US/PCT 66, wherein the second fin sealingroller includes the flexible connection between the hub element and theouter annulus of the second fin sealing roller.

US/PCT 68. The fin sealer of US/PCT 67, wherein the first fin sealingroller includes the flexible connection between the hub element and theouter annulus of the first fin sealing roller.

US/PCT 69. A method of sealing superimposed edges of a finned web bodywith first and second sealing rollers, the method comprising maintaininga nominal face-to-face relation between an outer annulus of the firstsealing roller and an outer annulus of the second sealing roller byflexibly connecting a hub of the second sealing roller with the outerannulus of the second sealing roller, whereby consistent sealing of thesuperimposed edges is enhanced.

US/PCT 70. The method of US/PCT 69 further comprising flexiblyconnecting a hub of the first sealing roller with the outer annulus ofthe first sealing roller.

US/PCT 71. A method of sealing a web body comprising: supporting a firstthermally conductive sealing jaw on a first rotor; supporting a secondthermally conductive sealing jaw on a second rotor; and rotating thefirst and second rotors to bring first and second sealing jaws into anopposing relation in contact with the web body; the rotating of thefirst and second rotors including heating at least the first sealing jawof the first rotor and cooling the second rotor, whereby a transfer ofheat from the first sealing jaw to the second sealing jaw is promoted.

Further illustrative, non-exclusive examples of structures and methodsaccording to the present disclosure are presented in the followingenumerated paragraphs. It is within the scope of the present disclosurethat an individual step of a method recited herein, including in thefollowing enumerated paragraphs, may additionally or alternatively bereferred to as a “step for” performing the recited action.

While the present invention has been described and illustrated byreference to particular embodiments, those of ordinary skill in the artwill appreciate that the invention lends itself to variations notnecessarily illustrated herein. For this reason, then, reference shouldbe made solely to the appended claims for purposes of determining thetrue scope of the present invention.

We claim:
 1. A fin-sealing component of a packet making machine,comprising: a first roller comprising: a rigid outer annulus arranged torotatably bear against a first side of a fin of a tubular web structure;and a heater in thermal communication with the rigid outer annulus ofthe first roller to transfer heat to the fin sufficient to seal the webalong the fin as the fin is contacted with the rigid outer annulus ofthe first roller; a second roller comprising: a rigid outer annulusarranged to rotatably bear against an opposite side of the fin in anopposing, nominally face-to-face relation with the rigid outer annulusof the first roller; and a support of the rigid outer annulus of thesecond roller comprising a hub and a flexible connection between the huband the rigid outer annulus of the second roller, the flexibleconnection operative to maintain the face-to-face relation between therigid outer annulus of the first roller and the rigid outer annulus ofthe second roller, whereby consistent sealing of the fin seal isenhanced.
 2. A method of sealing superimposed edges of a finned web bodywith first and second sealing rollers, the method comprising maintaininga nominal face-to-face relation between an outer annulus of the firstsealing roller and an outer annulus of the second sealing roller byflexibly connecting a hub of the second sealing roller with the outerannulus of the second sealing roller, whereby consistent sealing of thesuperimposed edges is enhanced.
 3. A method of sealing a web bodycomprising: supporting a first thermally conductive sealing jaw on afirst rotor, supporting a second thermally conductive sealing jaw on asecond rotor; rotating the first and second rotors to bring the firstsecond sealing jaws into an opposing relation in contact with the webbody; and while rotating the first and second rotors heating at leastthe first sealing jaw of the first rotor and cooling the second rotor,whereby transfer of heat from the first sealing jaw to the secondsealing jaw is promoted.
 4. The method of claim 3, wherein the coolingincludes flowing coolant through a coaxial channel in the second rotor.